Metabo KGS 303 PLUS Owner's manual

115 168 6660 / 0110 - 3.0

KGS 303 Plus

Originalbetriebsanleitung. . . . . . . . . . . . . . .3

Original operating instructions . . . . . . . . . .17

Instructions d’utilisation originales . . . . . . .30

Manuale d’uso originale. . . . . . . . . . . . . . .45

A0246_30IVZ.fm

D DEUTSCH ENG ENGLISH

KONFORMITÄTSERKLÄRUNG DECLARATION OF CONFORMITY

Wir erklären in alleiniger Verantwortlichkeit, daß dieses Produkt mit den folgenden Normen

übereinstimmt* gemäß den Bestimmungen der Richtlinien**

We herewith declare in our sole responsibility that this product complies with the following

standards* in accordance with the regulations of the undermentioned Directives**

F FRANÇAIS NL NEDERLANDS

DECLARATION DE CONFORMITE CONFORMITEITSVERKLARING

Nous déclarons, sous notre seule responsabilité, que ce produit est en conformité avec les

normes ou documents normatifs suivants* en vertu des dispositions des directives **

Wij verklaren als enige verantwoordelijke, dat dit product in overeenstemming is met de

volgende normen* conform de bepalingen van de richtlijnen**

IT ITALIANO ES ESPAÑOL

DICHIARAZIONE DI CONFORMITÀ DECLARACION DE CONFORMIDAD

Noi dichiariamo sotto la nostra esclusiva responsabilità che il presente prodotto è conforme alle

seguenti norme* in conformità con le disposizioni delle normative **

Declaramos bajo nuestra exclusiva responsabilidad, que el presente producto cumple con las

siguientes normas* de acuerdo a lo dispuesto en las directrices**

PT PORTUGUÊS SV SVENSKA

DECLARAÇÃO DE CONFORMIDADE

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

Declaramos sob nossa responsabilidade que este produto está de acordo com as seguintes

normas* de acordo com as directrizes dos regulamentos **

Vi försäkrar på eget ansvar att denna produkt överensstämmer med följande standarder* enligt

bestämmelserna i direktiven**

FIN SUOMI NO NORGE

VAATIMUKSENMUKAISUUSVAKUUTUS SAMSVARSERKLÆRING

Vakuutamme, että tämä tuote vastaa seuraavia normeja* on direktiivien määräysten mukainen** Vi erklærer under eget ansvar at dette produkt samsvarer med følgende normer* henhold til

bestemmelsene i direktiv**

DA DANSK POL POLSKI

OVERENSSTEMMELSESATTEST OŚWIADCZENIE O ZGODNOŚCI

Hermed erklærer vi på eget ansvar, at dette produkt stemmer overens med følgende standarder*

iht bestemmelserne i direktiverne**

Oświadczamy z pełną odpowiedzialnością, Ŝe niniejszy produkt odpowiada wymogom

następujących norm* według ustaleń wytycznych **

EL Ελληνικές HU MAGYAR

∆ΗΛΩΣΗ ΑΝΤΙΣΤΟΙΧΕΙΑΣ MEGEGYEZİSÉGI NYILATKOZAT

∆ηλώνουµε µε ιδία ευθύνη ότι το προϊόν αυτό αντιστοιχεί στις ακόλουθες προδιαγραφές*

σύµφωνα µε τις διατάξεις των οδηγιών**

Kizárólagos felelısségünk tudatában ezennel igazoljuk, hogy ez a termék kielégíti az alábbi

szabványokban lefektetett követelményeket* megfelel az alábbi irányelvek elıírásainak**

CZ Čeština

LV

lietuvių

Souhlasné prohlášení Atbilstības deklarācija

Tímto na vlastní zodpovědnost prohlašujeme, že tento výrobek splňuje níže uvedené normy*

normativní nařízení**

Mēs, apakšā parakstījušies, ar šo deklarējam ar pilnu atbildību, ka šis produkts atbilst šādiem

standartiem* saskaĦā ar zemāk minēto Direktīvu norādījumiem **

SL Slovenski

BG БЪЛГАРСКИ

IZJAVA O SKLADNOSTI ДЕКЛАРАЦИЯ ЗА СЪОТВЕТСТВИЕ

S polno odgovornostjo izjavljamo, da so stroji izdelani z upoštevanju standardov* in z

upoštevanjem regulativov navedenih v Direktivh**

Ние декларираме на собствена отговорност, че този продукт е в съответствие със

следните норми* съгласно предписанията на директиви**

ET Eesti LT Latviešu

VASTAVUSDEKLARATSIOON Suderinamumo aktas

Käesolevaga deklareerime täielikul enda vastutusel, et see toode on vastavuses järgmiste

standarditega* vastavalt allnimetatud direktiivides**

Mes vienpusiškai garantuojame, kad šis produktas atitinka sekančius standartus* pagal žemiau

minimas Nuostatas**

SK slovenčina RO Românã

Konformné prehlásenie Declaratie de conformitate

Prehlasujeme s plnou zodpovednosťou, že tento výrobok zodpovedá nasledovným normám*

podľa ustanovení smerníc**

Declaram pe proprie raspundere ca acest produs corespunde urmatoarelor norme*, conform

dispozitiilor directrivelor**

Volker Siegle

D - 72622 Nürtingen

Nürtingen, 05.01.2010 1001322

Kapp-Gehrungssäge/ crosscut - mitre saw

KGS 303 - KGS 303 PLUS

** 2006/42/EG, 2004/108/EG

* DIN EN 61029-1 (2003), DIN EN 61029-2-9 (2003), DIN EN 61000-2-3 (1995+A14), DIN EN 61000-3-3 (2002),

DIN EN 55014-1 (2000), DIN EN 55014-2 (1997), EN ISO 3744 (1995), DIN EN 62079 (2001)

Dokumentationsbevollmächtigter/ responsible person for documentation/ Chargé de la documentation

Metabowerke GmbH

Metabo-Allee 1

Director Innovation, Research and Development

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17

ENGLISH

1. Components and Parts (standard delivery)

12 4 5

6

7

8

9

10

1112

13

15

16

17

18

19

22

23

3

14

20

21

1 Handle

2 ON/OFF switch

3 Holder for Allen key 6 mm

4 Motor

5 Track arm guide bars

6 Track arm locking screw

7 Transport locking pin

8 Cutting depth limiter

9 Sawhead tilt locking lever

10 Hinged fence

11 Rotating table

12 Table insert

13 Rotating table lock screw

14 Saw base

15 Fence

16 Retractable blade guard

17 Saw blade lock

18 Safety lock

19 Sawhead

20 Laser guide

21 Auxiliary fence

22 Dust spout adaptor

(for connection of dust collector)

Tools

23 Allen key 6 mm

Machine documents

– Operating instructions

– Spare parts list

XA0040E4.fm Original operating instructions

18

ENGLISH

1. Components and Parts

(standard delivery) ....................17

2. Please read first! .......................18

3. Safety .........................................18

3.1 Specified conditions of use .........18

3.2 General safety instructions..........18

3.3 Symbols on the machine.............19

3.4 Safety devices.............................20

4. Installation and transport .........20

5. Special product features ..........21

6. Machine details .........................21

7. Initial operation .........................22

7.1 Connection of a dust collector.....22

7.2 Mains connection ........................22

8. Operation ...................................22

8.1 Standard cross cuts ....................22

8.2 Mitre cuts.....................................23

8.3 Bevel Cuts...................................23

8.4 Compound mitre cuts ..................24

8.5 Grooving......................................24

8.6 Auxiliary Fence............................24

9. Care and maintenance..............25

9.1 Changing the Saw Blade.............25

9.2 Drive belt tensioning....................26

9.3 Kerf plate replacement ................26

9.4 Adjustments ................................26

9.5 Machine cleaning ........................27

9.6 Machine storage..........................27

9.7 Maintenance................................27

10. Tips and tricks...........................27

11. Available accessories..........27/60

12. Repairs.......................................27

13. Environmental Protection ........28

14. Trouble Shooting ......................28

15. Technical specifications...........28

15.1 Available saw blades...................29

These instructions have been written in

a way which facilitates learning of how to

safely operate your saw. These instruc

-

tions should be used as follows:

− Read these instructions before use.

Pay special attention to the safety

information.

− These instructions are intended for

persons having a basic technical

knowledge of the operation of

machines such as the one

described herein. If you have no

experience whatsoever, we strongly

recommend to seek the advise of an

experienced person.

− Keep all documents supplied with

this machine for future reference.

Retain proof of purchase in case of

warranty claims.

− This machine must not be sold or

lent to someone else without being

accompanied by these operating

instructions and all other machine

documents.

− The equipment manufacturer is not

liable for any damage resulting from

neglect of these operating instruc-

tions.

Information in these instructions is

denoted as under:

Danger!

Risk of personal injury or

environmental damage.

Risk of electric shock!

Risk of personal injury

by electric shock.

Drawing-in/trapping haz-

ard!

Risk of personal injury

by body parts or clothing

being drawn into the

rotating saw blade.

Caution!

Risk of material damage.

Note:

Additional information.

− Numbers in illustrations (1, 2, 3, ...)

− denote component parts;

− are consecutively numbered;

− relate to the corresponding

number(s) in brackets (1), (2), (3)

... in the neighbouring text.

− Instructions to be carried out in a

certain sequence are numbered.

− Instructions which can be carried

out in any order are indicated by a

bullet point (•).

− Listings are indicated by an

En Dash (–).

3.1 Specified conditions of

use

This saw is intended for cross cuts,

bevel cuts, mitre cuts, and compound

mitre cuts of strips, profiled ledges, etc.

Grooving is also possible as well. Only

such materials suitable for cutting by the

saw blade fitted may be cut (see "Tech

-

nical specifications" for available saw

blades).

The permissible workpiece dimensions

must be observed (see "Technical speci-

fications").

Stock having a round or irregular cross

section (such as firewood) must not be

cut, as it can not be securely held during

cutting. When sawing thin stock layed on

edge, a suitable auxiliary fence must be

used for firm support.

Any other use is not as specified.

Unspecified use, alteration of the

machine, or use of parts not approved

by the equipment manufacturer can

cause unforeseeable damage!

3.2 General safety instruc-

tions

• When using this machine observe

the following safety instructions, to

minimize the risk of personal injury

or material damage.

• Please also observe the special

safety instructions in the respective

chapters.

• Where applicable, follow the legal

directives or regulations for the pre

-

vention of accidents pertaining to

the use of crosscut saws.

A

General hazards!

• Keep your work area tidy – a messy

work area invites accidents.

• Be alert. Know what you are doing.

Set out to work with reason. Do not

operate the tool while under the

influence of drugs, alcohol or medi

-

cation.

• Consider environmental conditions:

keep work area well lighted.

• Prevent adverse body positions.

Ensure firm footing and keep your

balance at all times.

• Do not operate the tool near inflam-

mable liquids or gases.

• This tool shall only be started and

operated by persons familiar with

crosscut saws, and who are at any

time aware of the dangers associ

-

ated with the operation of such tool.

Persons under 18 years of age shall

use this tool only in the course of

their vocational training, under the

supervision of an instructor.

• Keep bystanders, particularly chil-

dren, out of the danger zone. Do not

permit other persons to touch the

tool or power cable while it is run

-

ning.

• Do not overload the machine – see

chapter 15, "Technical Specifica

-

tions", for more information on the

performance range and limitations

of this machine.

B

Danger! Risk of electric shock!

• Do not expose tool to rain.

Do not operate tool in damp or wet

environment.

Prevent body contact with earthed

objects such as radiators, pipes,

cooking stoves, refrigerators when

operating this tool.

Table of Contents

2. Please read first!

3. Safety

19

ENGLISH

• Do not use the power cable for pur-

poses it is not intended for.

A

Risk of injury by moving parts!

• Do not operate the tool without

installed guards.

• Always keep sufficient distance to

the saw blade. Use suitable feeding

aids, if necessary. Keep sufficient

distance to driven components

when operating the tool.

• Wait for the saw blade to come to a

complete stop before removing cut

-

offs, scrap, etc. from the work area.

• Cut only work pieces of dimensions

that allow for safe and secure hold

-

ing while cutting.

• Do not attempt to stop the saw

blade by pushing the workpiece

against its side.

• Ensure the tool is disconnected from

power before servicing.

• Ensure that when switching on (e.g.

after servicing) no tools or loose

parts are left on or in the tool.

• Unplug if the tool is not used.

A

Cutting hazard, even with the

cutting tool at standstill!

• Wear gloves when changing cutting

tools.

• Store saw blade in such manner that

nobody will get hurt.

A

Risk of sawhead kickback (the

saw blade is caught in the workpiece

and the sawhead kicked up all of a

sudden)!

• Make sure the saw blade is suitable

for the workpiece material.

• Hold the handle firmly. When the

saw blade enters the work piece, the

kickback risk is particularly high.

• Cut thin or thin-walled workpieces

only with fine-toothed saw blades.

• Always use sharp saw blades.

Replace blunt saw blades at once.

Increased risk of kickback when a

blunt tooth gets caught by the work

-

piece's surface.

• Do not jam workpieces.

• Avoid lateral pressure on the saw

blade when grooving – use a stock

clamp.

• If in doubt, check workpiece for

inclusion of foreign matter (e.g. nails

or screws).

• Never cut several workpieces at the

same time – and also no bundles

containing several individual pieces.

Risk of personal injury if individual

pieces are caught by the saw blade

uncontrolled.

c

Drawing-in/trapping hazard!

• Ensure that no parts of the body or

clothing can be caught and drawn in

by rotating components (no neck

-

ties, no gloves, no loose-fitting

clothes; contain long hair with hair-

net).

• Never attempt to cut any workpieces

which contain

− ropes,

− strings,

− cords,

− cables or

− wires, or to which any of the

above are attached.

A

Hazard generated by insuffi-

cient personal protection gear!

• Wear ear protection.

• Wear safety glasses.

• Wear dust mask.

• Wear suitable work clothes.

• Wear non-slip shoes.

A

Risk of injury by inhaled wood

dust!

• Dust of certain timber species (e.g.

beech, oak, ash) can cause cancer

when inhaled. Work only with a suit

-

able dust collector attached to the

saw. The dust collector must comply

with the data stated in the technical

specifications.

• Ensure that as little as possible

wood dust will get into the environ-

ment:

− remove wood dust deposit in the

work area (do not blow away!);

− fix any leakages on the dust col-

lector;

− ensure good ventilation.

A

Hazard generated by modifica-

tion of the machine or the use of non-

OEM parts not tested and approved

by the manufacturer!

• Assemble tool in strict accordance

with these instructions.

• Use only parts approved by the

equipment manufacturer. This

applies especially for:

− saw blades (see "Technical

Specifications" for stock nos.);

− safety devices (see "Technical

specifications" for stock nos.).

• Do not change any parts.

A

Hazard generated by tool

defects!

• Keep tool and accessories in good

repair. Observe the maintenance

instructions.

• Before any use check tool for possi-

ble damage: before operating the

tool all safety devices, protective

guards or slightly damaged parts

need to be checked for proper func

-

tion as specified. Check to see that

all moving parts work properly and

do not jam. Make sure that all parts

and accessories are properly

installed and safely secured to

ensure the safe and trouble-free

operation of the machine.

• Do not use damaged or warped saw

blades.

•

Damaged protection devices or parts

must be repaired or replaced by a

qualified specialist. Have damaged

switches replaced by a service cen

-

tre. Do not operate tool if the switch

can not be turned ON or OFF.

• Keep handles free of oil and grease.

A

Risk of injury by noise!

• Wear ear protection.

• For reasons of noise protection do

not use warped saw blades. A

warped blade is exiting vibrations to

an especially large extent, which

means noise.

A

Danger from blocking work-

pieces or workpiece parts!

If blockage occurs:

1. Switch machine OFF.

2. Unplug mains cable.

3. Wear gloves.

4. Clear the blockage using a suitable

tool.

3.3 Symbols on the machine

Danger!

Disregard of the follow-

ing warnings can lead to

severe personal injury or

material damage.

Read instructions.

Do not reach into the run-

ning saw blade.

Wear safety goggles and

hearing protection.

Do not operate tool in moist

or wet environment.

Do not carry tool at

the handle; the han-

dle is not designed to

bear the weight of the

tool.

20

ENGLISH

Information on the nameplate:

3.4 Safety devices

Retractable blade guard

The retractable blade guard (32) pro-

tects against unintentional contact with

the saw blade and from chips flying

about.

Both segments of the retractable blade

guard must always return automatically

into their starting position: when the saw

-

head is lifted up, the sawblade must be

covered all around.

Safety lock

The safety lock (33) prevents the retract-

able blade guard from unintentional

opening.

For cutting the safety lock is pushed to

the side (arrow). Only then can the saw

-

head be lowered, opening the retracta-

ble blade guard.

After the cut is made - and the sawhead

is in its upper starting position - the

retractable blade guard is locked again

by the safety lock.

Hole for padlock

The hole (34) provided in the ON/OFF

switch can be used for blocking the

switch with a padlock.

A

Caution!

Do not carry tool at the handle; the

handle is not designed to bear the

weight of the tool. To carry, hold the

tool at both sides of the base.

Installation

1. Lift the tool out of the box with the

help of another person.

3

Note:

If the saw is put on the machine

stand:

do not install rubber feet!

2. Tip the machine over the install the

rubber feet:

− The machine's feet must be

accessible from both sides.

− The machine must rest securely

in its tipped over position.

3. Fit nut (38) into the hole on the

underside of the rubber foot.

4. Put hexagon socket screw

(35)

from

the top through the machine base.

Put washer

(36)

on the screw and

screw rubber foot

(37)

on with nut

(38)

.

5. Tighten rubber foot hand-tight. To

do so, counter the screw with the

Allen key.

6. Tighten screw hand-tight with the

Allen key.

7. Place tool on a suitable base:

− All four feet must firmly rest on

the base.

− The ideal height of the base is

800

mm.

− The saw must stand securely,

even when cutting larger work

pieces.

8. Push the sawhead slightly down and

pull the transport locking pin (39) out

– the sawhead can then be fully

lifted.

Transportation

1. If necessary, adjust the cutting

depth limiter (40) to the maximum

depth of cut.

(24) Manufacturer

(25) Serial number

(26) Machine designation

(27) Motor specifications (see also

"Technical Specifications")

(28) Year of make

(29) CE-mark – This machine con-

forms to the EC directives as per

Declaration of Conformity

(30) Waste disposal symbol –

Machine can be disposed of by

returning it to the manufacturer

(31) Dimensions of permissible saw

blades

25

26

27

28 29 31

24

30

32

4. Installation and transport

33

34

35

36

37

38

39

40

21

ENGLISH

2. Lower the sawhead and push the

transport locking pin

(39) in.

3. Keep the packing for future use, or

separate by material and dispose of

in an environmentally friendly man

-

ner.

− 96° cutting angle range for bevel

cuts (48° left thru 48° right) with five

positive stops.

− 110 ° cutting angle range for mitre

cuts (50 ° left thru 60 ° right) with ten

positive stops.

− Soft start.

− Integrated cutting depth stop for

grooving.

− Perfect for mobile use because of its

low weight and small dimensions.

− Precise and sturdy die-cast alumin-

ium construction.

− TCT saw blade.

− Unproblematic saw blade change by

saw blade lock; no dismounting of

the retractable blade guard required.

− Maximum dept of cut 81 mm.

− The track arm provides for up to

300

mm cutting width.

− Ergonomic control for both left-

handers and right-handers.

− Installation of auxiliary fence possi-

ble.

3

Note:

In this chapter the essential oper-

ating elements of the machine are intro-

duced.

The proper use of the saw is detailed in

chapter "Operation". Read this chapter

before using the saw for the first time.

ON/OFF switch

• To turn the motor ON:

Press and hold the ON/OFF switch

(41).

• To turn the motor OFF:

Release the ON/OFF switch.

Rotating table

For mitre cuts the rotating table (42),

after loosening the locking screw (43),

can be turned by 50° to the left and 60°

to the right.

The rotating table engages at positive

stops at the 0°, 15°, 22.5°, 30°, 45°, and

60° position.

A

Caution!

In order to prevent the mitre angle

from changing during cutting, the

rotating table's locking screw must

be tightened (also when engaged at

the positive stops!).

Push/pull action

The track arm permits the cutting of

workpieces having a larger cross sec

-

tion. The track can be used for all type of

cuts (standard cross cuts, mitre cuts,

bevel cuts, compound mitre cuts).

When it is not required, arrest the track

arm with the locking screw (44).

Cutting depth limiter

Together with the track arm, the cutting

depth limiter (45) makes grooving possi-

ble.

Hinged fence

The hinged fence (46) permits the saw-

head to tilt up to 48° to the right for bevel

cuts.

A

Caution!

To provide firm support for the work-

piece (as much supporting area as

possible), the hinged fence is to be

used as under:

• Sawhead tilted between 22.5° and

48° to the right: loosen screw (47)

5. Special product features

6. Machine details

41

42 43

44

45

46

47

22

ENGLISH

and swing the hinged fence to the

rear.

• Sawhead tilted between 22.5 ° and

48° to the left: swing the hinged

fence up and tighten screw

(47).

Bevel tilt setting

After loosening the ratchet lock lever

(48) at the rear, the sawhead tilts step-

lessly up to 48° from vertical to the left or

right.

A

Risk of crushing!

There is a risk of crushing your fin-

gers between the ratchet lock lever

and the track arm holder. Always

position the ratchet lock lever (by

pulling out and turning) so that there

is sufficient space between lock lever

and track arm holder.

The track arm holder engages at positive

stops at the 0°, 22.5°, and 45 ° position.

A

Caution!

In order to prevent the angle of incli-

nation from changing during cutting,

the ratchet lock lever must be tight-

ened (also when engaged at a posi-

tive stop!) .

7.1 Connection of a dust col-

lector

A

Danger!

Wood dust of certain species (e.g.

oak, beech, ash) can cause cancer

when inhaled: use a dust collector

− when using the saw in enclosed

spaces;

− when using the saw over

extended periods (more than 1/2

hour per day);

− when cutting oak, beech or ash.

Dust spout adaptor installation

• Push on the dust spout adaptor (49)

as illustrated.

7.2 Mains connection

B

Danger! High voltage

• Operate this machine in dry sur-

roundings only.

• Operate the machine only on a

power source meeting the follow-

ing requirements (see also "Tech-

nical Specifications"):

− mains voltage and system fre-

quency conform to the voltage

and frequency shown on the

machine´s rating label;

− fuse protection by a residual

current operated device (RCD)

of 30

mA sensitivity;

− Outlets properly installed,

earthed, and tested.

• Position power supply cable so it

does not interfere with the work

and is not damaged.

• Protect power supply cable from

heat, aggressive liquids and

sharp edges.

• Use only rubber-jacketed exten-

sion cables of sufficient lead

cross-section (3 x 1.5 mm

2

).

• Do not pull on power supply

cable to unplug.

A

Danger!

• Before starting any work, check

to see that the safety devices are

in proper working order.

• Use personal protection gear.

• Assume proper operating posi-

tion:

− at the front of the saw;

− in front of the saw;

− to the side of the line of cut.

• Risk of crushing! When tilting the

sawhead, keep your hands out of

the track arm holder's tilting

range! Hold at the sawhead.

• If the type of work requires, use

the following:

− work support – for long stock,

which would otherwise fall off

the table on completion of the

cut;

− dust collector.

• Cut only stock of dimensions that

allow for safe and secure holding

while cutting.

• Use an auxiliary fence if small

cutoffs will result when cutting.

• Always hold the workpiece down

on the table and do not jam it. Do

not attempt to stop the saw blade

by exerting lateral pressure. Risk

of injury if the saw blade is

blocked.

8.1 Standard cross cuts

Maximum workpiece cross section

(dimensions in mm):

Starting position:

− Transport locking pin pulled out.

− Sawhead fully raised.

− Cutting depth limiter set to maxi-

mum depth of cut.

− Rotating table in 0° position, the

locking screw of the rotating table is

tightened.

− Motorhead in vertical (90°) position,

bevel tilt locking lever tightened.

− Hinged fence on top of the fence

and secured.

− Track arm not extended.

− Locking screw of the track arm loos-

ened (if workpiece width requires).

48

7. Initial operation

49

8. Operation

Width approx. 300

Height approx. 81

23

ENGLISH

Cutting the work piece:

1. Hold workpiece against the fence.

2. Push the safety lock to the side and

press and hold the ON/OFF switch.

3. Slowly swing the sawhead fully

down, holding the handle firmly.

When sawing, exert only moderate

pressure to prevent the motor speed

to drop too much.

4. For wider workpieces pull the saw-

head forward (towards the opera-

tor).

5. Cut workpiece in a single pass.

6. Release the ON/OFF switch and let

the sawhead slowly return to its

upper starting position.

8.2 Mitre cuts

3

Note:

A mitre cut cuts the workpiece at

an angle against the rear guide edge.

Maximum workpiece cross section

(dimensions in mm):

Starting position:

− Sawhead fully raised.

− Cutting depth limiter set to maxi-

mum depth of cut.

− Motorhead in vertical (90°) position,

bevel tilt locking lever tightened.

− Hinged fence on top of the fence

and secured.

− Track arm not extended.

− Locking screw of the track arm loos-

ened.

Cutting the work piece:

1. Loosen the locking screw (51) of the

rotating table (50).

2. Set to desired angle.

3

Note:

The rotating table engages at

positive stops at the 0°, 15°, 22.5°, 30°,

45°, and 60° position.

3. Tighten the rotating table's locking

screw.

4. Cut workpiece as detailed under

"Standard cross cuts".

8.3 Bevel Cuts

3

Note:

A bevel cut cuts the workpiece at

an angle other than 90° against its sur

-

face.

Maximum workpiece cross section

(dimensions in mm):

Starting position:

− Sawhead fully raised.

− Cutting depth limiter set to maxi-

mum depth of cut.

− Rotating table in 0° position, the

locking screw of the rotating table is

tightened.

− Track arm not extended.

− Locking screw of the track arm loos-

ened.

Cutting the work piece:

1. If the sawhead is to be tilted

between 22.5 ° and 48° to the right,

swing the hinged fence down.

2. Loosen the ratchet lock lever (52)

for sawhead tilt at the rear of the

saw.

Rotating table position

Width

approx.

Height

approx.

15° 288 81

22.5° 275 81

30° 257 81

45° 210 81

50° 190 81

60°

right

148 81

50 51

Width

approx.

Height

approx.

Motor head inclination

22.5°

left

300 70

22.5 °

right

300 65

45 °

left

300 50

45 °

right

300 25

48 °

left

300 45

48 °

right

300 20

52

24

ENGLISH

3. Tilt the motorhead slowly into the

desired position.

3

Note:

The track arm holder engages at

positive stops at the 0°, 22.5°, and 45°

position.

4. Tighten the sawhead tilt locking

lever.

5. Cut workpiece as detailed under

"Standard cross cuts".

8.4 Compound mitre cuts

3

Note:

The compound mitre cut is a

combination of mitre and bevel cut. This

means the workpiece is cut at an angle

other than 90° against the rear guide

edge and against its surface.

A

Danger!

When cutting compound mitres the

saw blade is much more exposed

than normally - increased risk of

injury. Always keep sufficient dis

-

tance to the saw blade.

Maximum workpiece cross section

(dimensions in mm):

Starting position:

− Sawhead fully raised.

− Cutting depth limiter set to maxi-

mum depth of cut.

− Rotating table locked in desired

position.

− Sawhead tilted to desired angle

against the workpiece's surface and

locked.

− If the sawhead is to be tilted

between 22.5 ° and 48° to the right,

swing the hinged fence down.

− Locking screw of the track arm loos-

ened.

− Track arm not extended.

Cutting the work piece:

• Cut workpiece as detailed under

"Standard cross cuts".

8.5 Grooving

3

Note:

Together with the track arm, the

cutting depth limiter makes grooving

possible. With grooving no parting cut is

made, but the workpiece is cut to a cer

-

tain depth only.

A

Risk of kickback!

When grooving it is especially impor-

tant no lateral pressure is applied to

the saw blade. Otherwise the saw

-

head may be kicked up abruptly! Use

a stock clamp when grooving. Avoid

lateral pressure on the sawhead.

Starting position:

− Sawhead fully raised.

− Sawhead tilted to desired angle

against the work piece's surface and

locked.

− Rotating table locked in desired

position.

− Locking screw of the track arm loos-

ened.

− Track arm not extended.

Cutting the work piece:

1. Adjust cutting depth limiter (53) to

desired cutting depth and secure

setting with locking nut.

2. Hold workpiece against the fence.

3

Note:

For the groove to be cut at the

desired depth across the whole work-

piece width, a suitable spacer strip

needs to be placed between workpiece

and fence.

3. Push the safety lock to the side and

press and hold the ON/OFF switch.

4. Slowly swing the sawhead fully

down, holding the handle firmly.

When sawing, exert only moderate

pressure to prevent the motor speed

to drop too much.

5. When sawing, pull sawhead forward

(towards the operator).

6. Groove workpiece in a single pass.

7. Release the ON/OFF switch and let

the sawhead slowly return to its

upper starting position.

8.6 Auxiliary Fence

3

Note:

Use the auxiliary fence when

making vertical cuts in work pieces

higher than the saw's fence. Bevel cuts

are only possible without the auxiliary

fence in place.

Installing the auxiliary fence:

1. Put washers on carriage bolts (54) .

2. Slide carriage bolts (54) into fence

extrusions.

Width with sawhead tilted approx.

22.5 °

left

22.5 °

right

48 °

left

48 °

right

Rotating table position

15° 288 288 288 288

22.5° 275 275 275 275

30° 257 257 257 257

45° 210 210 210 210

50° 190 190 190 190

60°

right

148 148 148 148

Height with sawhead tilted approx.

22.5 °

left

22.5 °

right

48 °

left

48 °

right

Rotating table position

15° 70 65 45 20

22.5° 70 65 45 20

30° 70 65 45 20

45° 70 65 45 20

50° 70 65 45 20

60°

right

70 65 45 20

53

54

25

ENGLISH

3. Loosen Phillips head screw (55) by

one turn.

4. Set auxiliary fence halves against

the fence, for proper positioning

guide the carriage bolts from above

into the slots

(56) of the fence.

5. Put bushes (57) on carriage bolts.

6. Screw on star knobs (58) clockwise

on the carriage bolt and tighten

hand-tight, so the fence halves can

still be moved for adjusting.

7. Move fence halves against the kerf

plate opening.

8. Tighten star knobs.

9. Press auxiliary fence against the

fence and tighten Phillips head

screw

(55) again.

A

Danger!

Unplug before servicing.

− Repair and maintenance work other

than described in this section should

only be carried out by qualified spe

-

cialists.

− Replace defective parts, especially

of safety devices, only with genuine

replacement parts. Parts not tested

and approved by the equipment

manufacturer can cause unforeseen

damage.

− Check that all safety devices are

operational again after each service.

9.1 Changing the Saw Blade

A

Danger!

Directly after cutting the saw blade

may be very hot – burning hazard! Let

a hot saw blade cool down. Do not

clean a hot saw blade with combusti

-

ble liquids.

Risk of injury, even with the blade at

standstill. When loosening and tight-

ening the arbor bolt, the retractable

blade guard must encompass the saw

blade. Wear gloves when changing

blades.

1. To arrest the saw blade, pull the

saw blade lock

(59) forward. At the

same time slowly turn the saw blade

by hand, until the saw blade lock

engages.

2. Remove the arbor bolt (60) from the

saw spindle (left-handed thread!).

3. Unlock the retractable blade guard

and open it.

4. Remove the following parts from the

saw spindle:

− arbor bolt (60),

− outer blade flange (61),

− saw blade (62),

− inner blade flange (63).

5. Clean clamping surfaces of:

− saw spindle,

− inner blade flange,

− saw blade,

− outer blade flange,

− arbor bolt.

A

Danger!

Do not use cleaning agents (e.g. to

remove resin residue) that could cor

-

rode the light metal components of

the saw; the stability of the saw would

be adversely affected.

6. Put the inner blade flange (63) on

the saw spindle.

A

Danger!

Fit the inner blade flange correctly!

Otherwise the saw may be blocked, or

the saw blade could work loose! The

inner blade flange is in the correct

position when the chamfered collar

(65) shows to the right and the spring

ring groove (64) shows to the left.

7. Mount the new saw blade (62) –

observe the rotational direction (the

arrows on both saw blade and blade

guard must point in the same direc

-

tion)!

55

56

57

58

9. Care and maintenance

59

60 61 6362

64 65

26

ENGLISH

A

Danger!

Use only saw blades conforming to

standards and which are designed for

the maximum speed (see "Technical

specifications") – when using unsuit

-

able or damaged saw blades, parts

might be hurled away explosive-like

by the centrifugal force.

Do not use:

− saw blades made of high speed

steel (HSS);

− damaged saw blades;

− cut-off wheel blades.

A

Danger!

− Mount saw blade using only gen-

uine parts.

− Do not use loose-fitting reducing

rings; the saw blade could work

loose.

− Saw blades have to be mounted

in such way that they do not wob

-

ble or run out of balance and can

not work loose during operation.

8. Put outer blade flange (61) on –

the two flanks must fit over the flats

of the saw spindle!

9. Screw on the arbor bolt (60) (left-

handed thread!) and tighten with the

Allen key fingertight.

To arrest the saw blade, use the

saw blade lock (59).

A

Danger!

− Do not extend arbor bolt tighten-

ing wrench.

− Do not tighten arbor bolt by hit-

ting the assembly wrench.

10. Check the function. To do so, lower

the sawhead:

− The retractable blade guard must

open without touching the saw

blade or any other parts.

− When returning the sawhead in

the starting position the retracta-

ble blade guard must automati-

cally encompass the saw blade.

− In the upper starting position of

the sawhead the safety lock must

lock the retractable blade guard

to prevent unintentional opening.

− Check the saw blade lock – the

saw blade must turn freely.

9.2 Drive belt tensioning

The drive belt, running on the right-hand

side of the sawhead behind a plastic

cover, needs to be re-tensioned if it can

be depressed more than 3 mm halfway

between the two pulleys.

To check, re-tension and change:

1. Remove the plastic cover (66):

Loosen the screw (67) and detach

the engagement hook on the rear

side of the plastic cover.

2. Check belt tension by thumb pres-

sure.

If the drive belt needs to be re-ten-

sioned or replaced:

− Loosen the four motor screws by

approx. one turn.

− Re-tension or replace the drive

belt. To re-tension slide the motor

to the rear.

− Tighten motor fastening screws

crosswise.

3. Replace the plastic cover (66) and

secure with the screw.

9.3 Kerf plate replacement

A

Danger!

If the table insert is damaged there is

a risk that small parts may become

stuck between table insert and the

saw blade, causing the saw blade to

jam. Replace damaged table inserts

immediately!

1. Swing the hinged fence (68) down.

2. Take the fence (69) off.

3. Lever the table insert (70) up with a

screwdriver. Doing so will damage

the table insert; it can not be used

again.

4. Fit new table insert and let engage.

5. Reinstall the fence (69).

6. Swing the hinged fence up (70) and

secure it.

9.4 Adjustments

Fence adjustment

1. Swing the hinged fence down.

2. Loosen the fastening screws (71) of

the fence.

3. Using the two screws at the rear of

the fence (arrow) adjust the fence

position, until it is exactly 90° to the

saw blade with the rotating table

locked in the 0° position.

4. Tighten the fastening screws of the

fence.

5. Swing the hinged fence up and

secure it.

Mitre angle indicator adjustment

1. Adjust the indicator's (73) position

by means of the screw (72), until the

value indicated coincides with the

rotating table's positive stop.

3

Note:

The rotating table engages at

positive stops at the 0°, 15°, 22.5°, 30°,

45°, and 60° position.

Bevel tilt positive stop adjustment

1. Lock the track arm holder (74) in the

0° position.

66

67

68

6970

71

72 73

27

ENGLISH

2. Loosen the two hexagon socket

head cap screws

(75) at the rear of

the saw by approx. one turn.

3. Adjust the track arm holder until the

saw blade is at exactly 90° against

the rotating table.

4. Tighten the two hexagon socket

head cap screws

(75) at the rear of

the saw again.

5. Adjust the indicator's (76) position,

after loosening the screw (77) until

the value indicated coincides with

the current positive stop position of

the track arm holder.

3

Note:

The track arm holder engages at

positive stops at the 0°, 22.5°, and 45°

position.

9.5 Machine cleaning

Remove chips and saw dust with brush

or vacuum cleaner from:

− setting devices;

− the operating elements;

− motor vent slots;

− space below table insert.

9.6 Machine storage

A

Danger!

• Store the saw in such way that it

cannot be used or tampered with

by unauthorized persons.

• Make sure that nobody can get

injured by the stored machine.

A

Caution!

• Do not store saw unprotected

outdoors or in damp environ

-

ment.

• Observe the permissible ambient

conditions (see "Technical Speci

-

fications").

9.7 Maintenance

Prior to every use

• Remove saw dust and chips with

vacuum or brush.

• Check power cable and power cable

plug for damage; if necessary have

damaged parts replaced by a quali

-

fied electrician.

• Check all moving parts to see that

they can move freely across their

whole range of travel.

Periodically, depending on operating

conditions

• Check drive belt condition and ten-

sion, correct if necessary.

• Check all screwed joints, retighten if

necessary.

• Check pull-back springs of the saw-

head (the sawhead must return by

spring power to its upper starting

position), replace if necessary.

− For long stock use suitable supports

on both sides of the saw.

− When performing bevel cuts, hold

the work piece on the right side of

the saw blade.

− Use auxiliary fence when sawing

small cut-offs (this may be a suitable

board, fastened with four screws to

the fence).

− When cutting warped or bent work

pieces, make sure that you place

work piece so that the convex side

(i.e. the outer side of the bow)

against the fence.

− Do not cut stock standing on edge;

always place it flat on the rotating

table.

− Keep the supporting surfaces clean

– in particular, remove resin residue

with a suitable cleaning and mainte

-

nance spray.

For special tasks the following accesso-

ries are available at your specialized

dealer – see back cover for illustrations:

A Dust collection attachment

Protects your health and keeps the

shop clean.

B Dust spout adaptor

To connect the dust collection

attachment to a dust collector.

C Work clamp

Required for precision cuts and cut-

ting of non-ferrous metals.

D Table extension, left

Required for cutting long stock;

extends to 3000 mm;

folds for space saving storage.

E Table extension, right

Required for cutting long stock;

extends to 3000 mm;

folds for space saving storage.

F Table extension, left

Required for cutting long stock;

extends to 1600 mm;

folds for space saving storage.

G Table extension, right

Required for cutting long stock;

extends to 1600 mm;

folds for space saving storage.

H Work stand

For a secure machine stand and

optimal working height;

folding, ideal for mobile use.

I TCT saw blade 250 x 2.8 / 2.0 x 30

24 alternate bevel teeth

for wood and non-laminated parti-

cle board.

J TCT saw blade 250 x 2.4 / 1.8 x 30

48 alternate bevel teeth

For wood and panels.

K TCT saw blade 250 x 2.4 / 1.8 x 30

60 alternate bevel teeth

For wood, panels and thick-walled

plastic extrusions

L TCT saw blade 250 x 2.8 / 2.0 x 30

80

trapezium-flat teeth

For wood, panels, ducting, NF

extrusion, high-quality veneered

sheets and laminates.

A

Danger!

Repairs to electric tools must be car-

ried out by qualified electricians only!

Electric tools in need of repair can be

sent to the service centre of your coun

-

try. Refer to the spare parts list for the

address.

Please attach a description of the fault to

the electric tool.

74 75

76

77

10. Tips and tricks

11. Available accessories

12. Repairs

28

ENGLISH

The machine's packing can be 100%

recycled.

Worn out power tools and accessories

contain considerable amounts of valua

-

ble raw and rubber materials, which can

be recycled.

These instructions are printed on paper

produced with elemental chlorine-free

bleaching process.

This section describes problems and

malfunctions which you should be able

to resolve yourself. If the measures

detailed here do not solve your problem,

see under "Repairs".

A

Danger!

Many accidents happen particularly

in connection with problems and

faults. Therefore please note:

• Always unplug before servicing.

• Check that all safety devices are

operational again after each fault

service.

Motor does not run

No mains voltage

• Check cables, plug, outlet and

mains fuse.

No crosscut function

Transport locking pin engaged:

• Pull transport locking pin out.

Safety lock engaged:

• Actuate the safety lock.

Only little sawing performance

Saw blade blunt (possibly tempering

marks on blade body):

Saw blade not suitable for material being

cut (see chapter "Technical specifica

-

tions");

Saw blade warped:

• Replace saw blade (see chapter

"Maintenance").

Saw vibrates heavily

Saw blade warped:

• Replace saw blade (see chapter

"Maintenance").

Saw blade incorrectly mounted:

• Mount saw blade correctly (see

chapter "Maintenance").

Saw squeals when starting

Drive belt tension too low:

• Retension the drive belt (see chap-

ter "Maintenance - Drive belt ten-

sioning").

Stiffness of rotating table

Saw dust build-up under rotating table:

• Remove saw dust.

13. Environmental Protection

14. Trouble Shooting

15. Technical specifications

Voltage V 230 (1∼ 50 Hz) 110 (1∼ 50 Hz)

Current draw A 8.4 15.9

Fuse protection A 10 (time-lag) -

Motor capacity*(power input P1, S6 20% - 5 min) kW 1.8 1.6

Protection class IP 20 20

Degree of protection II II

Saw blade speed min

-1

5020 5020

Cutting speed m/s 66 66

Saw blade diameter (outer) mm 250 250

Arbor bore mm 30 30

Dimensions

Machine in packing

− Length / width / height

Machine ready to work, rotating table in 90°position, c/w suction port

− Length / width / height

mm

800 / 600 / 450

575 / 900 / 595

800 / 600 / 450

575 / 900 / 595

Maximum workpiece cross section

Standard cross cuts

− width / height

Mitre cuts (rotating table 45°)

− width / height

Bevel cutss (track arm holder 45° left)

− width / height

Compound mitre cuts (rotating table 45° / sawhead 48 ° left)

− width / height

mm

300 / 81

210 / 81

300 / 50

210 / 45

300 / 81

210 / 81

300 / 50

210 / 45

Weight

Machine in packing

Machine ready to work

kg

26

20

26

20

Permissible ambient temperature for operation

Permissible temperature for transport and storage

°C

0 to + 40

29

ENGLISH

15.1 Available saw blades

Noise emission according to DIN EN 61029-1 **

Sound power level L

WA

Sound pressure level at operator ear L

PA

dB (A)

118

104

118

104

Effective value of weighted acceleration (Vibration at handle)

Uncertainty K

m/s

2

m/s

2

< 2.5

1.5

< 2.5

1.5

Dust collector (not included in standard delivery)

− Suction port diameter

− Minimum air volume flow

− Minimum vacuum at suction port

− Minimum air speed at suction port

mm

m

3

/h

Pa

m/s

35

550

740

20

35

550

740

20

* This machine is specially designed for the high momentary loads of crosscutting. The motor reaches the stated power of

1800 watts at S6 20% 5 min. (intermittend periodic duty-type with starting). This means that this saw can be operated for 1 minute

at full-load rating (1800 watts) within a 5 minute operating period. The motor has to deliver these 1800 watts only under extreme

load conditions - during normal crosscutting it is subjected to much lower loads. With lower loads the duty cycle of the motor

increases substancially. Thus, when used as specified, because of its high reserve capacity, overheating or overloading of the

motor is not possible.

** The values stated are emission values and as such do not necessarily constitute values which are safe for the workplace.

Although there is a correlation between emission levels and environmental impact levels, whether further precautions are neces

-

sary cannot be derived from this. Factors influencing the actually present environmental impact level in the workplace include the

characteristics of the work area and other noise sources, i.e. the number of machines and other neighbouring work processes. Also,

permissible workplace values may vary from country to country. This information is intended to assist the user in his estimate of

hazards and risks.

Voltage V 230 (1∼ 50 Hz) 110 (1∼ 50 Hz)

Diameter Arbor bore Tooth rake No. of teeth Used for Stock-no.

250 mm 30 mm 5° neg. 24

alternate top bevel

teeth

wood,

non-lamintated

particle board

628 013 000

250 mm 30 mm 5° neg. 48

alternate top bevel

teeth

wood,

panels

628 047 000

250 mm 30 mm 5° neg. 60

alternate top bevel

teeth

wood,

panels

thick-walled plas-

tic extrusions

628 048 000

250 mm 30 mm 6 ° neg. 80

trapezoidal-flat

teeth

wood,

panels

Cable ducting,

NF profiles,

high-quality

veneered sheets,

laminates

628 088 000

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